2003 CHRYSLER CARAVAN lock

OPERATION
The Transfer Unit provides the power to the rear
wheels through a hypoid ring gear and pinion set.
DIAGNOSIS AND TESTING
SEAL IDENTIFICATION
For accurate seal diagnosis, repair seal name and
location is critical. Refer to (Fig. 1), (Fig. 2), (Fig. 3)
and (Fig. 4) for correct seal name and location.
FLUID LEAK DIAGNOSIS
When diagnosing fluid leaks on the Power Transfer
Unit two weep holes are provided to diagnose certain
seal leaks. These holes are located on the bottom side
of the assembly (Fig. 5).
If fluid leak is detected from either weep hole, seal
replacement is necessary.Do not attempt to repair
the leak by sealing weep holes,they must be kept
clear of sealants for proper seal operation.
If fluid is leaking from weep hole A (Fig. 5) the
type of fluid leaking will determine which seal needs
to be replaced. If the fluid leaking is red in color
(transmission fluid) this indicates that the Transmis-
sion differential carrier seal should be replaced. If
the fluid leaking is light brown (gear lube) this indi-
cates that the Power Transfer Unit input seal should
be replaced. For replacement of these seals refer to
Power Transfer Unit Service Procedures.
1 - PLUG 18 - CASE-PTU 35 - SHIM
2 - WASHER FLAT 19 - PINION-PTU 36 - TAPERED ROLLER BEARING
3 - SEAL RING 20 - O-RING 37 - SHAFT ASSY. FRONT L.H.
4 - SNAP RING 21 - SHIM 38 - SEAL RING
5 - BALL BEARING 22 - TAPERED ROLLER BEARING 39 - OIL WIPER
6 - SEAL RING 23 - COVER-PTU CASE REAR 40 - RETAINER DIFFERENTIAL BEARING
7 - COVER-PTU CASE END 24 - FLANGE TUBE-PTU-OUTPUT ASSY. 41 - SHAFT DIFFERENTIAL PINION
8 - TAPERED ROLLER BEARING 25 - LOCK NUT-HEX FLANGE 42 - PIN
9 - SEAL RING 26 - O- RING 43 - CASE DIFFERENTIAL
10 - SEAL RING 27 - RETAINER PLATE 44 - TAPERED ROLLER BEARING CONE
11 - HEX HEAD SCREW 28 - O-RING 45 - SEAL RING
12 - SHAFT-PTU INPUT 29 - BRACKET 46 - SEAL RING
13 - GEAR-PTU RING 30 - THRUST WASHER 47 - PLUG
14 - TROUGH-PTU (RT.) 31 - SIDE GEAR-DIFFERENTIAL 48 - O-RING
15 - TROUGH-PTU (LT.) 32 - FINAL DRIVE GEAR 49 - SHIM
16 - TAPERED ROLLER BEARING 33 - PINION DIFFERENTIAL 50 - MAGNET
17 - HEX HEAD SCREW 34 - WASHER DIFFERENTIAL PINION 51 - DOWEL
52 - SHAFT ASSY. FRONT R.H.
53 - HEX HEAD SCREW
Fig. 1 Seal
1 - INPUT SHAFT
2 - P.T.U. CASE
3 - MAGNET
4 - INPUT SHAFT END SEAL
5 - OUTPUT SHAFT
6 - RING GEAR
7 - REAR COVER
Fig. 2 Seal Location
1 - REAR COVER
2 - END COVER
3 - OUTER HALFSHAFT SEAL
4 - P.T.U. CASE
5 - P.T.U. OUTPUT SEAL
RSPOWER TRANSFER UNIT21-3
POWER TRANSFER UNIT (Continued)
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(3) Tap on end cover ears to separate end cover
from case (Fig. 39).
(4) Pry out seal with a pry bar (Fig. 40).INSTALLATION
The input shaft end seal is located on the end of
the input shaft.
(1) Clean and inspect seal area.
(2) Remove input shaft from housing and stand on
soft block of wood. Install input shaft end seal with
seal installer 5065 and handle C-4171.
(3) Lubricate seal lip after installing seal into
input shaft.
(4) Clean sealing surfaces of the end cover and
P.T.U. case. Apply a bead of MopartGasket Maker,
Loctite Gasket Eliminator No. 518 or equivalent.
(5) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in the
sequence shown in (Fig. 41). Retighten first bolt after
all others are tight.
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly.
(7) Check and fill fluids as required.
Fig. 39 Side Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
Fig. 40 Seal Removal
1 - POWER TRANSFER UNIT
2 - PRYBAR
3 - SEAL
Fig. 41 Bolt Tightening Sequence
21 - 16 POWER TRANSFER UNITRS
INPUT SHAFT END SEAL (Continued)
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(9) Using Tool 6638A, disconnect clutch hydraulic
circuit quick connect (located on slave cylinder tube).
Remove clutch slave cylinder by depressing towards
case and rotating counter-clockwise 60É, while lifting
anti-rotation tab out of case slot with screwdriver
(Fig. 12).
(10) Remove engine left mount bracket.
(11) Remove starter motor (Fig. 13).
(12) Disconnect back-up lamp switch connector.
(13) Remove structural collar.
(14) Remove modular clutch assembly-to-drive
plate bolts.
(15) Position screw jack and wood block to engine
oil pan.
(16) Remove transmission upper mount through-
bolt from left frame rail.
(17) Lower engine/transaxle assembly on screw
jack.
(18) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 14).
(19) Obtain helper and transmission jack. Secure
transaxle to transmission jack and remove transaxle-
to-engine bolts.
(20) Remove transaxle from engine.
(21) Inspect modular clutch assembly, clutch
release components, and engine drive plate.
Fig. 12 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
Fig. 13 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 14 Transaxle Upper Mount
1 - MOUNT
2 - BOLT (4)
21 - 32 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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(10) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 20).(11) Raise vehicle on hoist.
(12) Remove front wheel/tires and halfshafts.
(13) Remove underbody splash shield.
(14) Drain transaxle fluid into suitable container.
(15) Remove front harness retainer and secure
harness out of way.
(16) Using Tool 6638A, disconnect clutch hydrau-
lic circuit quick connect (located on slave cylinder
tube). Remove clutch slave cylinder by depressing
towards case and rotating counter-clockwise 60É,
while lifting anti-rotation tab out of case slot with
screwdriver (Fig. 21).
(17) Remove engine left mount bracket (Fig. 22).
(18) Remove starter motor (Fig. 23).
(19) Disconnect back-up lamp switch connector.
(20) Position screw jack and wood block to engine
oil pan.
(21) Remove transmission upper mount through-
bolt from left frame rail.
(22) Lower engine/transaxle assembly on screw
jack.
(23) Remove four (4) upper mount-to-transaxle
bolts and remove mount (Fig. 24).
Fig. 19 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 20 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 21 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
21 - 34 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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INSTALLATION
INSTALLATION - 2.4L GAS
(1) Install modular clutch assembly to transaxle.
Assemble transaxle to engine.
(2) Install and torque transaxle-to-engine bolts to
95 N´m (70 ft. lbs.).
(3) Raise transaxle/engine assembly into position
and install upper mount through-bolt. Torque
through-bolt to 75 N´m (55 ft. lbs.).
(4) Remove screw jack.
(5) Install and torque modular clutch assembly-to-
drive plate bolts to 88 N´m (65 ft. lbs.)
(6) Install structural collar.
(7) Connect back-up lamp switch connector.
(8) Install starter motor into position (Fig. 78).
Install and torque bolts to 54 N´m (40 ft. lbs.).
(9) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).(10) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs (Fig. 79). While
depressing inward, rotate slave cylinder clockwise
60tÉ into position until nylon locating tab rests
within transaxle case cutout, and hydraulic tube is
vertical. Connect ªquick-connectº connection until an
audible ªclickº is heard. Verify connection by pulling
outward on connection.
(11) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(12) Lower vehicle.
Fig. 78 Starter Motor Removal/Installation
1 - STARTER MOTOR
2 - BOLT (3)
Fig. 79 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
RST850 MANUAL TRANSAXLE21-51
T850 MANUAL TRANSAXLE (Continued)
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(8) Install engine front mount bracket. Install and
torque bracket-to-transaxle bolts to 102 N´m (75 ft.
lbs.). Install and torque bracket-to-engine bolts to 68
N´m (50 ft. lbs.). Torque through-bolt and nut to 68
N´m (50 ft. lbs.).
(9) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs (Fig. 85). While
depressing inward, rotate slave cylinder clockwise
60É into position until nylon locating tab rests within
transaxle case cutout, and hydraulic tube is vertical.
Connect ªquick-connectº connection until an audible
ªclickº is heard. Verify connection by pulling outward
on connection.
(10) Install underbody splash panel.
(11) Install halfshafts and front wheel/tire assem-
blies. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
HALF SHAFT - INSTALLATION)
(12) Lower vehicle.
(13) Install right mount bracket to transaxle (Fig.
86).
(14) Connect gearshift cables to shift levers/cover
assembly (Fig. 87). Install cables into position at
mount bracket and secure with retaining clips.
Fig. 85 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
5 - QUICK CONNECT
Fig. 86 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
Fig. 87 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
21 - 54 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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SPECIFICATIONS - T850 MANUAL TRANSAXLE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Transaxle TypeConstant-mesh, fully synchronized 5-speed with integral
differential
Lubrication MethodSplash oil collected in case passage and oil trough and
distributed to mainshafts via gravity
Fluid Type ATF+4 (Automatic Transmission FluidÐType 9602)
GEAR RATIOS
GEAR RATIO (2.4L Gas) RATIO (2.5L TD)
1st 3.65 3.65
2nd 2.05 2.05
3rd 1.39 1.37
4th 1.03 0.97
5th 0.83 0.76
Reverse 3.47 3.47
Final Drive Ratio 3.77 3.77
Overall Top Gear 3.12 2.67
INPUT SHAFT
BLOCKER RING WEAR GAP
3rd Gear 0.856-1.539 mm (0.0338-0.0606 in.)
4th Gear 0.762-1.631 mm (0.030-0.064 in.)
GEAR END PLAY
3rd Gear 0.099-0.505 mm (0.004-0.020 in.)
4th Gear 0.048-0.457 mm (0.002-0.018 in.)
21 - 56 T850 MANUAL TRANSAXLERS
T850 MANUAL TRANSAXLE (Continued)
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INTERMEDIATE SHAFT
BLOCKER RING WEAR GAP
1st Gear 0.66-1.84 mm (0.026-0.072 in.)
2nd Gear 0.66-1.84 mm (0.026-0.072 in.)
5th Gear 0.86-1.54 mm (0.034-0.061 in.)
Reverse 0.77-1.63 mm (0.030-0.064 in.)
GEAR END PLAY
1st Gear 0.091-0.828 mm (0.004-0.033 in.)
2nd Gear 0.051-0.787 mm (0.002-0.031 in.)
5th Gear 0.102-0.762 mm (0.004-0.030 in.)
Reverse 0.066-0.805 mm (0.003-0.0317 in.)
DIFFERENTIAL
DESCRIPTION METRIC STANDARD
Differential Turning Torque 2.3-3.4 N´m 20-30 in. lbs.
Side Gear End Play (each side) 0.025-0.152 mm 0.001-0.006 in.
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, Differential
Cover-to-Case54 40 Ð
Bolt, End Cover-to-Case 28 Ð 250
Bolt, End Cover
Plate-to-Cover28 Ð 250
Bolt, Extension Housing-
to-Case28 Ð 250
Bolt, Reverse Idler
Shaft-to-Case54 40 Ð
Bolt, Ring Gear-to-
Differential Case95 70 Ð
Bolt, Shift Cover-to-Case 28 Ð 250
Nut, 5th Gear-to-Input
Shaft262 193 Ð
Plug, Drain 23 17 Ð
Screw, Input Bearing
Retainer12 Ð 105
Switch, Back-Up Lamp 23 17 Ð
Vent 7 Ð 60
RST850 MANUAL TRANSAXLE21-57
T850 MANUAL TRANSAXLE (Continued)
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